Thermoforming: Thermoforming sector in a boom phase

The global
thermoformed
packaging sector
is expected to
grow at a steady
CAGR of 6.3%,
says research firm
Transparency
Market Research
(TMR), during the
forecast period
of 2019-2024.
Meanwhile, CMT
Materials, GN
Thermforming and
Kiefel will present
new materials/
machinery at the
K2019 show in
October.

The thermoformed packaging market is also projected to reach a valuation of US$57.61
billion by the end of 2024. In 2018, the global thermoforming packaging market was
valued at over US$45 billion, says TMR.

In the report, titled “Thermoforming Packaging Market: Global Industry Analysis, Size,
Share, Growth, Trends and Forecast, 2019-2027,” TMR states that the massive demand
from food and pharmaceutical industries is anticipated to expand the global thermoforming
packaging market by 1.7 times during the forecast period.

It also states that the packaging industry is estimated to account for around 80% in terms
of market value and is projected to show fast-paced growth owing to the high demand.
A number of factors are pushing the growth, against the back of an expanding urban
population in emerging economies, with a penchant for packaged food products.
The thermoformed packaging market is segmented into clamshell, blister, skin, tubs, and
cups. Among these, the blister packaging segment is expected to outgrow other segments,
due to its high demand in the pharmaceuticals industry.

Pharmaceutical packaging has applications in pharmaceuticals for diverse purposes
including carrying, storing, and shipping of medicines, medical devices, as well as drug
dispensing systems. Thermoforming packaging products including blister packs have
emerged as key packaging solutions to carry, organize, and ship medical devices and
components through specific design specifications.

On the regional front, Asia Pacific and North America are two key regions driving
demand in the market. Presence of leading players in North America and increasing demand
for packaged food and beverages in Asia Pacific are the key growth factor boosting demand,
especially driven by increasing demand for packaged food and beverage products by the
urban populations in the emerging economies of China, India, and South Korea.

New technologies to aid growth

Against the back of strong growth for copolymer and thermoplastic plug materials as the
global plastics packaging market continues to grow, US-based CMT Materials, a provider
of plug-assist materials for the thermoforming industry, will showcase its range of Hytac
syntactic foams at K2019 in Düsseldorf, Germany, from 16-23 October 2019.

It will highlight the Hytac C1R and Hytac XTL, which
have enjoyed strong market acceptance, said the company,
adding that data-driven studies on the economic impact
of plug material selection show that consistency and
repeatability can be achieved in thermoforming,. In
particular, Hytac plug assists play a key role by helping
processors manage wall thickness variation, reduce
starting gauge and improve cycle times.

The company notes that the increased growth is
largely focused in food packaging applications in Europe
and Asia, with material shifts away from PS to PP and
new, multilayer films and adds that these more complex
polymers require more sophisticated plug assists. “In
some cases, there is a requirement for higher friction,
in others it’s easier release, and in still others it is for
new tougher thermoplastic syntactics,” it adds. In the
latter category, the company’s new syntactic foam offers
twice the toughness of B1X and features a new cellular
structure that yields a smoother surface, adding that the
unbreakable plug doesn’t scratch soft plastics.

The main trends driving demand for these technologies
are the growing popularity of ready-to-eat meals, changing
consumer habits and increasing disposable income in
emerging Asian economies. North American processors
also show continued growth in sectors such as large
bakery items, tamper-evident clamshells and medical
device packages.

The Hytac XTL plug assist is the industry’s first and only
material to combine the machined surface quality of epoxy
syntactic with the durability and dust-free machining of
thermoplastic syntactic foam. This is particularly important
when working with sticky or transparent plastics because
of the challenge of polishing thermoplastic syntactic
materials. A significant side benefit of the formulation is
increased toughness, allowing for very fine plug details,
noted CMT. It is suited for use with PP, PET, PE, APET,
CPET, HIPS, OPS, PETG, PLA, PS, PVC and RPET.

Also featured at K2019 is CMT’s Hytac CR, a copolymer
plug assist formulated with friction enhancer to carry
plastic deep into a cavity or specialty detail. Hytac C1R
provides three to four times the toughness of epoxy-based
syntactic foam.

Elsewhere, Canadian manufacturer of servo-driven
thermoforming machines GN Thermoforming Equipment
has developed a new form-cut-stack thermoformer that
targets low to medium-volume packaging production for
the food, medical and industrial markets.

The new GN580 thermoformer is a smaller version
of its successful GN800 launched at K2016 and will be
displayed at K2019. The first GN580 machine was sold to
a European packaging manufacturer early this year. The
company says it offers the same features as the GN800,
with integrated steel rule cutting press and stacking
station, suitable for all thermoformable materials. Other
features are the high degree of automation as well as ease
of tool change.

Meanwhile, Germany-based Kiefel will launch its
new generation steel rule pressure forming machine,
Speedformer KMD 78.2, at K2019. Featuring “intuitive”
user guidance for easy operation, the machine is said to
deliver higher productivity, process control and availability
compared to its predecessors, according to Kiefel.

The user guidance offers pictograms and graphics,
making the adjustment of machine parameters and fault
diagnosis easier. The display shows the entire forming
process and other important processes at a glance, with
Kiefel adding that this makes the complete process easy to
understand, even for non-experts.

A newly developed film feed table guides the film to
the film transport system, while an optimised forming air
vacuum system enables customers to produce improved
parts. The ergonomic tool change systems can also
significantly shorten set-up times.

“Ergonomics and data transparency are a matter of
course. And of course, in addition to common materials
and products, our new system can also process novel
film materials and produce even complex products whilst
consuming a minimal amount of energy," says Erwin
Wabnig, Director Packaging Division
at Kiefel.